Co-casting precious metal to an alternative material

ABSTRACT

A Co-Casting technique is described herein using Pins, Undercuts, Grooves, Rails that permit the attachment of a secondary precious metal to a primary alternative meta. The process of making a mold creating a model and casting a final worked piece uses wax filling of the recessed areas and the subsequent molding of the precious metal within the recessed areas in order to fill the aforementioned.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 61/766,096 filed Feb. 18, 2014, the entirety of which is incorporated by reference

FIELD OF THE INVENTION

The present invention is related to improvements in the attachment of one type of material to another. More particularly, the present invention provides a process whereby a precious metal can be attached to another material that is not as valuable as the first; this less valuable material defined by the jewelry industry as “alternative,” “contemporary,” or “non-traditional.”

BACKGROUND OF THE INVENTION

Just prior to the formation of Spectore Corp in 1983, Edward Rosenberg (Spectore's founder) was one of, if not the only American to pioneer and introduce refractory metals to the jewelry industry. Through the last 30 years contemporary materials (including but not limited to: the entire family of refractory metals titanium, niobium, zirconium, and tantalum as well as stainless steel, chrome cobalt and others deemed as alternative, contemporary, and new age materials—hereinafter referred to as “alternative materials” or “AM”) grew to become a staple accepted fine and fashion jewelry, gift and accessory material. Due to the supply, demand, and inflation, gold, platinum, silver, palladium, and the like have further increased in cost to such an extent that the average consumer finds it difficult to purchase items made purely of the aforementioned. As a consequence, jewelry retailers and customers have been forced by current market trends to cut back on their purchasing of now highly expensive items; thus, articles having precious metals such as rings, bracelets, jewelry, consumer products, giftware, personal and table top accessories, watches, and any form of decorative encasements have experienced a general decline in their respective market shares.

Because of this, many have begun to purchase items having materials outside of the traditional materials used in the industry; these are known in the common parlance of the industry as alternative materials. These alternatives were introduced and/or promoted by manufacturers stung by their falling sales; of these, Spectore Corporation was one of the principal if not the only pioneer of AM going back as early as 1980. Thus, a growing number of manufacturers have followed suit in that they rightly reacted to the cost driven decline by shifting production to articles containing tungsten, titanium, stainless steel, surgical stainless steel, platifina or rhodium based jewelry and many other types of alternative materials. As a result, customers now have the choice of articles using AM in providing the benefit of an inert material which is incredibly compatible with the skin and is highly durable.

However, people still like precious metal jewelry and there is still a great demand for these items if some solution to their exorbitant cost could be found. Accordingly, there remains a need in the art for a solution to this problem that overcomes the cited deficiencies of high upfront cost while still providing a valuable, precious metal article that conveys value over time.

SUMMARY

The invention provides a process for co-casting precious metal to an alternative material that overcomes the hereinafore-mentioned disadvantages of the heretofore-known devices and methods of this general type and that

With the foregoing and other objects in view, there is provided, in accordance with the invention, a co-casting method that includes creating an original design having unique criteria with a recessed area connecting a pattern in the design;

In another aspect, the pattern has a minimum depth of 0.5 mm.

In another aspect, the unique criteria ensures that a secondary metal adheres to a primary alternative metal.

In another aspect, wherein each pattern wall has an undercut to permit attachment of a secondary material.

In another aspect, making the original design into a mold.

In another aspect, creating a model using a metal and a pattern therein is coated with wax filling.

In another aspect, placing the model in an investment sprue.

In another aspect, casting the model with a secondary metal.

In another aspect, removing the model from the investment and immediately molding it with both metals together.

In another aspect, cleaning and completing the model.

These and other aspects, features, and advantages of the present invention will become more readily apparent from the attached drawings and the detailed description of the preferred embodiments, which follow.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred embodiments of the invention will hereinafter be described in conjunction with the appended drawings provided to illustrate and not to limit the invention, in which:

FIG. 1 presents a short group of images representing the depressions and undercuts, connecting rails and pin co-casting methods;

FIG. 2 represents a general explanation of the method of using depressions in co-casting an item;

FIG. 3 represents a general explanation of the method of using rails in co-casting an item; and

FIG. 4 represents a general explanation of the method of using pins in co-casting an item.

Like reference numerals refer to like parts throughout the several views of the drawings.

DETAILED DESCRIPTION

The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. For purposes of description herein, the terms “upper”, “lower”, “left”, “rear”, “right”, “front”, “vertical”, “horizontal”, and derivatives thereof shall relate to the invention as oriented in each individual figure. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

The concept taught herein is a laminated precious metal having matching contours with an alternative material found underneath. A securing area (hole, undercut, pin etc) or extended surface on the one or more sides (anywhere on piece) of the alternative material forms a convenient support piece for attachment of the top precious metal surface. Thus, this securing area(s) can be found anywhere about the surface that one using this concept would find it useful to locate a support surface about the alternative material article to be overlaid.

FIG. 1 presents a short group of images representing the depressions and undercuts, connecting rails and/or pin co-casting methods and includes other means as well as each of these techniques may be used alone or in combination. The images depict a ‘groove’ or depression in the surface of an article of jewelry made from an Alternative Material such as titanium; this groove or depression is to be filled with another material having a lower boiling point such as gold, silver etc. . . . . In this context, the word ‘groove’ means a depression that is a hollowed out area in the surface of a material such that the ‘groove’ forms the region for co-casting of a secondary material into the aforementioned hollow in the structure of a material. The basic process is to first SKETCH a design of an item then CREATE the DESIGN using CAD/CAM or by hand using wax CARVING. Then, the process may include using 1) ridges and/or undercuts, 2) connecting rails, and 3) pin co-casting are utilized to cast the two metals together creating a beautiful item.

FIG. 2 represents a process flow diagram relating to the method of using grooves, depressions and/or undercuts in co-casting an item. This process includes:

-   -   a. A wax or CAM part is created having a finished exterior         surface representing the finished article (ring in this example)         as it would be with both the alternative material and secondary         material together; thus, this part is completely full and is         without any undercuts and or grooves therein. It also has a base         having a thin rod sprue connecting the base to the article         itself     -   b. A primary mold is created by inserting the part made in step         ‘a’ by hand or CAM into rubber mold slabs having top and bottom         portions. A mold is made of this model and thus the article can         be duplicated over and over again.     -   c. A wax or CAM part is created having a finished exterior         surface representing the finished article (ring in this example)         as it would be with both the alternative material and secondary         material together; thus, this part is completely full and is         without any undercuts and or grooves therein. It also has a base         having a thin rod sprue connecting the base to the article         itself.     -   d. A production mold is created by inserting the part made in         step ‘c’ by hand or CAM into rubber mold slabs having top and         bottom portions. A mold is made of this model and thus the         article can be duplicated over and over again.     -   e. Then the production mold is utilized to create a finished         article over and over again. A ring or other article that has         been machined with grooves is filled with wax in the grooves         therein and is inserted into the production mold. A secondary         material such as gold or silver is injected into the mold with a         rapid burnout cycle thereby completing the article.

FIG. 3 represents a process flow diagram relating to the use of rails in co-casting an item. This process includes:

-   -   A) A wax or CAM part with a plurality of rails connecting ring         all the way around to trap secondary material forming a complete         ring.     -   B) A primary model is molded.     -   C) The primary model is filled with wax for secondary casting.     -   D) A completed Co-Cast, materials are molded together, then         primary model (2A) is placed inside for secondary wax injection         to repeat process.

Alternative process . . .

-   -   a. A wax or CAM part is created having a finished exterior         surface representing the finished article (ring in this example)         as it would be with both the alternative material and secondary         material together; thus, this part is completely full and is         without any undercuts and or grooves therein. It also has a base         having a thin rod sprue connecting the base to the article         itself     -   b. A primary mold is created by inserting the part made in step         ‘a’ by hand or CAM into rubber mold slabs having top and bottom         portions. A mold is made of this model and thus the article can         be duplicated over and over again.     -   c. A wax or CAM part is created having a finished exterior         surface representing the finished article (ring in this example)         as it would be with both the alternative material and secondary         material together; thus, this part is completely full and is         without any undercuts and or grooves therein. It also has a base         having a thin rod sprue connecting the base to the article         itself     -   d. A production mold is created by inserting the part made in         step ‘c’ by hand or CAM into rubber mold slabs having top and         bottom portions. A mold is made of this model and thus the         article can be duplicated over and over again.     -   e. Then the production mold is utilized to create a finished         article over and over again. A ring or other article that has         been machined with grooves is filled with wax in the grooves         therein and is inserted into the production mold. A secondary         material such as gold or silver is injected into the mold with a         rapid burnout cycle thereby completing the article.

FIG. 4 represents a process flow diagram relating to the use of pins in co-casting an item. A pin is a hole in the inside surface of the item that reaches through the body of the item to the ridges above that are to be filled with secondary metal. This process includes:

-   -   A) A model is created using casting or CAM/CAD.     -   B) A primary metal model molded.     -   C) Primary metal is placed on wax sprues and pattern is filled         with wax.     -   D) Co-casted model is molded together.     -   E) Primary metal model (3A) is recreated and placed in secondary         mold and injected with wax and cast again to apply secondary         material to repeat the process.

Co-Casting Process

-   -   A) An original design is created with a recessed cut away area         connecting a pattern throughout the design.     -   B) The pattern must have certain criteria that will insure the         secondary metal over Black Ti (AM) or other AM will adhere to         the model. It should be noted that Black Ti is used an exemplary         metal and any other AM may be used in connection with the         process described herein.     -   C) The pattern may have a minimum depth of 0.4 mm and width of         generally less than 0.5 mm throughout the model; however, it         should be understood that these dimensions are only exemplary         amounts and that sizes greater or less than these are         contemplated.     -   D) The pattern must have an undercut in each pattern wall to         adhere secondary material.     -   E) The model is then created in Black Ti (AM) or any other         material defined as alternative using machining and or         traditional modeling and or Titanium casting methods.     -   F) The Black Ti (AM) model will be made into a mold for future         production.     -   G) The Black Ti (AM) model will be coated with wax, so as to         fill in the pattern, and then placed on a traditional investment         sprue.     -   H) The Black Ti (AM) model and wax combination is then cast at         temperatures ranging from 500° F. to 2900° F. with the secondary         metal using traditional jewelry investment in a rapid burnout         cycle of 4-5 hours.     -   I) The Co-cast model is removed from the investment and         immediately molded with both metals together.     -   J) The Co-cast design is cleaned and completed.     -   K) The process may then repeat at any of the aforementioned         steps.

This type of co-casting of precious metals gold (all Karats), silver, platinum and palladium, to what is defined as contemporary or alternative metals; including but not limited to: titanium and all refractories (Niobium/columbium), zirconium, and Tantalum), stainless steel, chrome cobalt, Tungsten carbide, ceramics, etcetera. This technique applies to consumer products and/or further for jewelry, giftware, personal and table top accessories, watches, and any form of decorative encasements. The combined piece made of precious metal and an alternative material can be attached to giftware, accessories wherein the attachment is through woodworking adhesive, screws, bolt, nut, welding, heat treatment, plastic or similar protrusion, and slot insertion.

In an alternative embodiment of the present invention the co-cast process is accomplished by creating a foundation in the contemporary (or alternative material). The reason being that it is generally the material with the higher melting point. The foundation product may be produced in any number of methods, including casted, machined, fabricated, etched or otherwise. The foundation is prepared with recesses, cavities, undercuts, holes or other openings that are created to capture and secure the lower melting point or softer materials (precious metal or otherwise including copper, bronze, brass, etc). Once the foundation material has been properly cleaned and prepared for the addition of secondary or more materials, wax or other burn out material is inserted into the chosen areas. The wax may be inserted in any number of methods including by hand, injected in molds (rubber or metal) or other. The next step is to place the piece with the wax inserted onto what the industry calls investment or other shell material. This investment or shell material is poured as a liquid into a canister along with the waxed metal foundation material. Once the liquid investment is cured and hardened the canister is place in an oven where the wax is burnt out and the molten metal of the secondary materials are poured in to fill the cavities. The investment is then cooled and removed, leaving the co-cast product ready to finish.

FINAL OPTIONAL METHOD for affixing the precious material to the AM. By wrapping the wax around (more than half way) to completely around the AM. In doing this, once the precious material is melt around the AM portion, the base piece is trapped in the surrounding material.

The above-described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the invention. Many variations, combinations, modifications or equivalents may be substituted for elements thereof without departing from the scope of the invention. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all the embodiments falling within the scope of the appended claims. 

What is claimed is:
 1. A co-casting method comprising the steps of: creating an original design having a unique criteria with a recessed area connecting a pattern in the original design.
 2. The co-casting method of claim 1, wherein the pattern has a minimum depth of 0.5 mm.
 3. The co-casting method of claim 1, further comprising: ensuring the unique criteria enables a secondary metal adheres to a primary alternative metal.
 4. The co-casting method of claim 3, wherein the pattern includes a side wall with an undercut to permit attachment of a secondary material.
 5. The co-casting method of claim 1, further comprising: making the original design into a mold.
 6. The co-casting method of claim 5, further comprising: creating a model using a metal and a pattern therein; and coating the pattern with wax filling.
 7. The co-casting method of claim 6, further comprising: placing the model in an investment sprue.
 8. The co-casting method of claim 7, further comprising: casting the model with a secondary metal.
 9. The co-casting method of claim 8, further comprising: removing the model from the investment sprue and immediately molding it with both metals together.
 10. The co-casting method of claim 9, further comprising: cleaning and completing the model.
 11. A Co-Casting method comprising the steps of: creating a primary mold model having a plurality of recessed areas therein; filling the plurality of recessed areas in the primary mold model with a wax for secondary casting; and molding a precious metal in the recessed areas and repeating the process.
 12. The Co-Casting method of claim 11, wherein the recessed area is from a group comprising of: a ridge, an undercut, a pin, and a rail.
 13. A co-casting process comprising the steps of: providing a part with a depression throughout an outside wall; molding a primary model is molded; filling the primary model with wax for secondary casting; and completing a co-cast as the metals are molded together such that the primary model is placed inside for secondary wax injection to repeat process. 